Vane Seal Assembly for Thermal Expansion and Air Leakage

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Solution Overview

Problem

Implementing ceramic matrix composite (CMC) materials in airfoils of gas turbine engines faces unique challenges due to thermal expansion mismatches and potential abrasion issues between components.

Innovation Solution

A vane assembly design featuring a seal with multiple fingers configured to bias against a collar projection, utilizing a biasing member to ensure a compliant and non-abrasive fit, reducing air leakage and maintaining sealing despite thermal expansion and misalignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If a seal is used to prevent air leakage between the spar piece and vane piece, then air leakage is reduced, but thermal expansion mismatches and abrasion issues arise between the seal and collar projection

Engineering Contradiction:
Improveair leakageVSAvoidseal durability
Core Design Contradiction:
Loss of energyVSReliability

Solution Approach 1:

The seal includes multiple fingers that can flex and deform to accommodate thermal expansion mismatches between the seal and collar projection. The fingers are configured to contact the collar projection at multiple discrete contact points rather than a continuous surface, allowing the seal to maintain contact while flexing during thermal cycles. This flexibility prevents abrasion and maintains sealing effectiveness over time.

Inventive Principle:
Principle #30Flexible shells and thin films

Solution Approach 2:

The seal is divided into multiple separate fingers instead of a single continuous sealing element. Each finger independently contacts the collar projection at discrete points, allowing differential thermal expansion of each finger without compromising the overall seal. The segmented structure reduces stress concentration and prevents abrasion by distributing contact forces across multiple points.

Inventive Principle:
Principle #1Segmentation

2Loss of energy

If the seal is biased against the collar projection to maintain sealing contact, then air leakage is prevented, but abrasion increases between the seal and collar projection

Engineering Contradiction:
Improveair leakageVSAvoidabrasion
Core Design Contradiction:
Loss of energyVSObject-affected harmful factors

Solution Approach 1:

The seal is divided into multiple separate fingers that contact the collar projection at discrete points rather than a continuous surface. This segmentation reduces the total contact area and distributes the biasing force across multiple points, minimizing abrasion on the collar projection while maintaining effective sealing contact.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The seal fingers are designed to be flexible, allowing them to conform to the collar projection surface while maintaining light contact pressure. The flexibility enables the seal to achieve sealing contact without requiring high biasing forces, thereby reducing abrasion. The fingers can flex to accommodate surface irregularities and thermal expansion without increasing contact stress.

Inventive Principle:
Principle #30Flexible shells and thin films

3Ease of manufacture

If a rigid seal design is used to maintain structural integrity, then manufacturing is simplified, but thermal expansion mismatches cause sealing failure

Engineering Contradiction:
Improveseal constructionVSAvoidsealing effectiveness
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The seal incorporates flexible fingers that can deform to accommodate thermal expansion mismatches between the seal and the collar projection. This flexibility is achieved through the finger geometry and material selection, allowing the seal to maintain contact during thermal cycles without complex mechanical compensation mechanisms, keeping the design relatively simple to manufacture.

Inventive Principle:
Principle #30Flexible shells and thin films

Solution Approach 2:

The seal transitions from a static rigid structure to a dynamic flexible structure that can adapt its shape in response to thermal expansion. The fingers are designed with appropriate flexibility to move and conform during operation, allowing the seal to maintain effectiveness under varying thermal conditions while remaining manufacturable using standard techniques.

Inventive Principle:
Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The design effectively reduces air leakage and maintains a secure seal despite thermal expansion and misalignment, enhancing the operational efficiency and durability of CMC airfoils in gas turbine engines.

Implementation Method 1

A biasing member is configured to bias the seal towards the collar projection

Methodology Applied
Scientific EffectElasticity: Elasticity

Data Source

PatentUS12486777B2Vane with seal
Publication Date: 2025.12.02 RTX CORP
  • US12486777B2 patent drawing
  • US12486777B2 patent drawing
  • US12486777B2 patent drawing

AI summary

An airfoil vane assembly includes a vane piece defining a first vane platform, a second vane platform, and a hollow airfoil section joining the first vane platform and the second vane platform. The first vane platform defines a collar projection therefrom. A spar piece defines a spar platform and a spar extends from the spar platform into the hollow airfoil section. The spar platform includes a radial opening defined by first and second axial faces. The radial opening is configured to receive the collar projection, and a groove in the first axial face. A seal is situated in the groove. The seal seals against the collar projection and a biasing member is configured to bias the seal towards the collar projection. A method of assembling a vane is also disclosed.